Manufacturing Process

Shipping Cases

Shipping Cases, and equipment cases are used for computers, laptops, monitors (both flat panel and CRT), plasma or LCD screens, printers, electronic instruments, medical devices, and more. Cases By Source serves the industrial market with hundreds of shipping cases to fit every requirement. Choose from our line of stock cases or have a stock case custom-fitted with a foam interior to protect your valuable equipment and instrumentation.

All of our shipping cases are ATA-approved which means they are Air Transport Association rated and suitable for shipment on the airlines. Many styles are classified as ATA 300, Category 1 — the highest standard for an airline transport container (a minimum of 100 common carrier trips). Our economical cases also meet military spec. (MIL-SPEC) standards; many of the styles are airtight and watertight.

Stock cases often ship the same day. We offer Pelican, SKB, and our own Hardigg-style cases, among others.

From Low Profile Shipping Cases to Roto-X and Utility ones, our shipping cases are manufactured using the rotational molded, injection molded, thermoformed processes; we also offer our fabricated ATA style-SpectraCase. These custom ATA road cases can be outfitted with foam interiors, pull handles, or casters and unlimited design choices to meet your exact requirements. In as few as five days, we can build a case to the unique size requirement of your specific application.

We also carry a full line of stock ATA SpectraCases–more than 250 different sizes all available to ship within 2 days.

At Source, we will meet your Shipping Case budget and exceed your expectations. Proper cushioning can be designed to alleviate your specific shipping concerns; our design engineers can help you to determine the proper degree of protection and support for any size, weight, and shaped product that requires a shipping case with a customized case insert.

The Challenge

Tired of waiting after trade shows for our shipping crates, and observing trade show exhibitors’ poor packing habits and insufficient product protection inspired us to create a better solution for clients who needed a more efficient method of transport for displays and merchandise.

The Response

Inspired by cases we've made for the military—the ones that allow our troops to set up impromptu workstations and communication posts in the field—we designed a case that not only functions as a shipping container, but also as convertible exhibit fixtures.

The Solution

For a recent trade show, we packed a 10’ x 10’ booth’s contents in two of our new 48” x 28” x 30” Booth in a Box trade show cases. We designed the case lids to transform into tables, placed them next to the bases, and draped them to make standard 8’ tables. We used the 14.39 cubic feet—per case—of interior storage space for ancillary literature, coats, tools, and other non-essentials. And while we watched our fellow exhibitors inventory their freight and battle "popcorn," bubble wrap, packing tape, and banged-up corrugated containers, we simply removed the protective plastic wrap from our cases’ exteriors, lifted the lids, assembled the tables, and unpacked and placed our materials. All in less than half the time it took other exhibitors to set up the same size booths. At the end of the trade show, we packed the cases, folded down the table legs into the lid, placed the lids on the cases, and left for the airport…back home an entire day early.

Case Study: Aircraft Brake Case

The Challenge

A leading aerospace company approached Source looking for a reusable solution for transporting 70-pound airplane brakes. Their previous shipping solution consisted of stray, makeshift, and leftover boxes with spray-in foam.

The Response

The client wanted a case that would not only secure and protect the delicate but weighty equipment, but one that would also reinforce corporate identification. Our ATA SpectraCase with a custom foam insert provided the durability and customization they sought.

The Solution

We designed a custom-fabricated ATA Case with plywood laminated to ABS. The case features spring-loaded recessed handles, a fully removable lid for easier lifting and full access to the brakes, reinforced corners for protection during the shipping cycle, a stackable design for convenient storage and transport, and a silk-screened logo and custom color ABS panels for brand identification and reinforcement. The interior was engineered with durable polyethylene foam ergonomically designed with four cutouts that allow for two-person access to the weighty and sensitive materials. At the client’s request, we also added an instructional label on the lid’s interior and affixed it to the foam with an aggressive adhesive to withstand handling.

Case Study: Temperature Controlled Shipping Case

The Challenge

A world-renowned beverage company required a custom solution for transporting liquids from far-off, sometimes Third-World nations, to testing facilities on all corners of the globe. When plastic corrugated shipping containers were used, the bottles shattered, the boxes buckled, and unpredictable temperature fluctuations easily overwhelmed the packages.

The Response

Drawing upon our experience with the medical industry, we designed a budget-conscious soft-side case that could handle the heavy—75 pounds—but sensitive payload and maintain a critical temperature range for sometimes week-long stretches.

The Solution

We designed a soft-side case with a top-loading tray insert constructed of expanded polypropylene foam engineered to increase air flow. Gel packs were inserted into the case walls. We customized the insert to protect the payload, while allowing the temperature to be maintained within the critical tolerance. We built the cases of ballistic nylon strong enough to withstand world-wide travel, handling, and environmental fluctuations. The outer, rectangular case was strengthened with firm polyethylene foam sewn into the lining of waterproof nylon that was added to keep the cold air inside. Molded plastic corners were also attached to the exterior to maintain shape and ruggedize the solution.

For ease of handling, we added recessed inline-skate wheels doubled up to support the heavy payload, and a handle with an ergonomic rubber grip for comfort. The final addition of document pouches and silk-screened branding and handling information established these cases as the optimal packaging solution for the client's needs.

Case Study: Medical Device Instrument Case

The Challenge

A California-based spinal company relied on flimsy corrugated packaging and commercially-produced dunnage to protect their anatomically-driven instrumentation. They came to Cases By Source to explore more effective alternatives and, in the course of sending their equipment for measurement, experienced first-hand proof of their need for cases: The tools were damaged in transit.

The Response

To protect the client’s sensitive equipment, we suggested a durable but portable case that would guarantee protection and still offer the aesthetics of a sales demo kit. The Pelican 1510 Carry-On Case pairs durable, lightweight construction with a travel-friendly design that meets FAA carry-on size regulations—a perfect solution for this client’s needs.

The Solution

Using our sophisticated structural design tools, we measured each piece of equipment in order to determine the most sensible layout for the custom interior. We then created 3D computer models of the instruments and proposed interior to provide the customer with a quick snapshot of the case before production commenced. For this client, we fabricated a closed-cell cross-linked, routed-foam custom insert to secure the items and display them in an efficient order inside the watertight, crushproof and dustproof case. This foam is available in a variety of densities with rich color saturations. For brand recognition and informational purposes, we added a scratchproof, personalized label to the exterior and a literature pouch was secured in the lid.